Nutritional bar and components

ABSTRACT

A nutrition bar which incorporates protein in the form of nuggets having high levels of selected proteins. By use of the nuggets of the invention, nutrition bars are formulated to have elevated levels of protein, yet good taste and other organoleptic properties. The nuggets according to the invention include greater than 50 wt % of a non-soy protein selected from the group consisting of milk protein, rice protein and pea protein, especially between 51 wt % and 99 wt %, more preferably between 52 wt % and 95 wt %, most preferably 55 wt % or above. The milk protein is preferably whey protein. The nuggets of the invention are preferably made using an extrusion process wherein the extrusion temperature is moderated so as to avoid damage to the whey proteins and concomitant off-taste. In this preferred process according to the invention, extrusion is conducted at temperatures of from 60 to 140° C., after which the protein is dried using a belt/conveyor drier or a fluid bed drier. In an alternate method of making the nuggets according to the invention, a lower extrusion temperature of up to 90° C. is used and one or more supercritical fluids are injected prior to extrusion to form a puffed product.

BACKGROUND OF THE INVENTION

Increasingly, a focus of modern preventive medicine is weight reduction.Excessive weight is frequently cited in reports concerning the surge incases of type 2 diabetes. Moreover, obesity is often mentioned indiscussions of other modern diseases, such as heart disease.

For years a debate has raged as to which class of nutrients, fats orcarbohydrates, are preferentially minimized to promote weight loss.Recently, much consumer attention has focussed on those who advocatereduction of carbohydrates and higher intakes of unsaturated fat and/orprotein.

An increasingly popular form for ingestion of nutrients for thoseseeking to lose weight is the nutrition bar. The nutrition bar providesa convenient vehicle for replacing a meal or for supplementing meals asa snack. While consumers express a preference for snacks and other foodswhich are more healthful and which can assist them to achieve theirweight loss goals, they show little inclination to sacrifice theorganoleptic properties of their favorite foods. Therefore, thesuccessful food formulator must improve the nutrient value of the foodwhile maintaining desirable organoleptic properties. High protein levelsare particularly difficult to incorporate into good tasting foods sincepopular proteins, such as soy, often have undesirable aftertastes.

Lanter et al. U.S. Pat. No. 5,683,739 is directed to extruded animalfeed nuggets comprising between about 90 and 99 wt % of at least oneprotein containing ingredient and between 1 and 6 wt % added fat. Thenugget is prepared by plasticizing a blend of at least oneprotein-containing ingredient, added fat, sulfur (if present), andwater, extruding the plasticized blend to form an animal feed nugget,and drying the extruded nugget to a water content of less than about 12wt %. Protein sources mentioned include oil seed meals such as soybeanmeal and cottonseed meal, and animal byproduct meals such as meat meal,poultry meal, blood meal, feather meal, and fish meal, plant byproductmeal such as wheat middlings, soybean hulls, and corn byproducts andmicrobial protein such as torula yeast and brewer's yeast. U.S. Pat.Nos. 5,540,932 and 5,120,565 also are directed to animal feed nuggetswhich contain, or may contain, protein.

Carr WO 02/096208 (New Zealand Dairy Board) is directed to a dried,enhanced solubility milk protein concentrate (MPC) containing at leastone monovalent salt added prior to drying. Preferred salts are sodiumand potassium salts. A method for preparing the MPC includes providingan MPC having at least 70% milk protein as dry matter in aqueoussolution or suspension, adding at least one monovalent salt in an amountthat confers enhanced solubility when dried, and drying the product.Preferably between the salt addition step and the drying step, adewatering step, preferably by evaporation, or a concentration step byultrafiltration and/or diafiltration, is undertaken. The MPC of theinvention can be used in cheese manufacture. The ratio of casein to wheyprotein is essentially that of milk.

According to Carr, a problem with MPCs and MPI (milk proteinisolates: >85% milk protein as dry matter) is that such products aregenerally very insoluble at cold temperatures. A problem is said to bethat they are associated with the formation of nuggets in the cheese.The solubility properties of the products are said to make the driedMPCs and MPIs advantageous in the preparation of a variety of products,for example, beverages. Also the dried MCPs and MPIs can be used incheese preparation to avoid nugget formation.

Bhaskar et at. WO 01/41578 is directed to dried milk proteinconcentrates and their use. The invention includes a process of cheesemanufacture using dried MPC or MPI having at least 70% dry matter asmilk protein.

Rizvi et al. U.S. Pat. Nos. 5,120,559 and/or 5,417,992 disclose use ofsupercritical fluids, such as CO₂ to extrude a food product.

WO 01/56402 discloses an alpha lipoic acid food supplement forincreasing lean muscle mass and strength. A source of amino acids may beincluded. Whey protein is said to be a preferred source of amino acids.Whey protein isolates, whey peptides, whey protein concentrate orhydrolyzed Whey protein may be used. Other proteins which may be usedinclude casein, other milk proteins, and albumins. The food supplementscan be in a variety of forms such as protein bars.

Portman U.S. Pat. No. 6,051,236 is directed to a nutritional compositionin dry powder form for optimizing muscle performance during exercise.The compositions may be in the form of an energy bar. Proteins such ascalcium caseinate, whey protein concentrate, whey protein isolate, soyprotein, casein hydrolysate, meat protein concentrate and yeastconcentrate are mentioned.

Gilles et al. U.S. Pat. No. 6,248,375 (Abbott Labs) discloses solidmatrix materials designed for the person with diabetes. It includes asource of fructose in combination with at least one nonabsorbentcarbohydrate. The two component carbohydrate system is said to blunt thepostprandial carbohydrate response. One of the forms for administrationmentioned is nutritional bars. Gilles et al. mention Ensure® Glucerna®Nutritional Bars as having 14% of total calories as protein in the formof soy protein, calcium caseinate, and corn protein. Choice dm® Bar iscited as a nutritional bar for people with diabetes and including 17.1%total calories as protein in the form of calcium caseinate, soy proteinisolate, whey protein concentrate, toasted soybeans, soy nuggets (soyprotein isolate, rice flour, malt, salt) and peanut butter. Gluc-O-Bar®is said to be a medical food designed for use in management of diabeteswhich includes up to 23% of total calories as protein in the form of soyprotein isolate, non fat dry milk, and peanut flour.

Gilles et al. use protein which it is said can include any proteinssuitable for human consumption, including casein, whey, milk protein,soy, pea, rice, corn, hydrolyzed protein and mixtures thereof. Thetypical amount of protein will be about 10%, to about 25% of totalcalories, most preferably about 15 to about 20% of total calories. It issaid that the solid matrix nutritional compositions may be made by coldextrusion techniques.

Proteint of St. Paul, Minn. makes a nugget having a whey protein levelof 50%.

Nuvex of Blue Earth, Minn. makes a nugget having a whey protein level of50%.

Various other foods have been described which mention nuggets which mayinclude proteins. These include U.S. Pat. Nos. 6,086,941, 6,010,738.

Anon, “Nutraceuticals-International,” 2000, Vol 5, p. 25 (from abstractnumber 548502) reports that a new milk-protein hydrolysate, ProdietF200, which is claimed to help people cope with stress, has beenmarketed by a French company, Ingredia. It is said to be suitable forfunctional foods such as chocolate bars. Also, a product based onhydrolysed why protein, Proxime Alpha sold by Borculo Domo Ingredients,is said to have beneficial effects on stress.

Swartz, ML, “Milk proteins and hydrolysates in nutritional foods,” “FoodIngredients Europe: Conference Proceedings, London, October 1994,published in “Maarssen: Processs Press Europe,” 1994, 73-81 (fromAbstract number 373368) is a review of recent developments in productionof milk proteins and hydrolysates for nutritional products. Applicationof milk proteins in 3 specific types of nutritional products, includingsports bars, are said to be discussed in detail.

Swartz, ML, “Food-Marketing-&-Technology”, vol 9, 4, 6, 9-10, 12, 20(from abstract number 1995-08-P0036) is a review of the nutritionalvalue, functional properties and applications of milk proteins and milkprotein hydrolysates. Applications in functional foods such as food barsfor athletes are considered.

Kaufman WO 01/33976 (Children's Research Hospital) is directed to amethod for treating a type 2 diabetic to decrease hypoglycemic episodesand/or diminish fluctuations in blood glucose outside of the normalrange, which comprises administering to the subject in an effectiveappetite suppressing amount a food composition, which can be a bar,which includes a slowly absorbed complex carbohydrate such as uncookedcornstarch. Soy protein, whey protein and casein hydrolysate arementioned as possible protein sources.

Keating et al. EP 768 043 (Bristol Meyers-Squibb) is directed to anutritional composition for use by diabetics containing a controlledabsorbed carbohydrate component. The carbohydrate component contains arapidly absorbed fraction such as glucose or sucrose, a moderatelyabsorbed fraction such as certain cooked starches or fructose and aslowly absorbed fraction such as raw corn starch. Preferred proteinsources are said to include whey protein, sodium caseinate, or calciumcaseinate, optionally supplemented with amino acids. Other preferredprotein sources include protein hydrolysates such as soy proteinhydrolysate, casein hydrolysate, whey protein hydrolysate, other animaland vegetable protein hydrolysates and mixtures thereof. Among the formsmentioned which the invention can take are a nutritional bar or cookie.The nutritional bars and cookies are preferably baked. The bar is madeby cold forming or extrusion. The granola bar of example 1 includes skimmilk powder and peanuts.

EP 306 733 is directed to a sugar free binder for foods which containssugar substitute and protein hydrolysate in a weight ratio of 3:1 to 1:3in agglomerated form (as granules).

DeMichele et al. U.S. Pat. No. 6,444,700 (Abbott Labs) is directed toimmunonutritional products said to be useful-in reducing theimmunological suppression said to result from stress. Solid nutritionalcompositions such as bars are mentioned. Soy proteins are mentioned aspossible ingredients for the solid compositions.

Despite the many previous efforts to formulate bars with proteins, thereis still a need for a good tasting nutrition bar having elevated levelsof protein.

SUMMARY OF THE INVENTION

The present invention is directed especially to a nutrition bar whichincorporates protein in the form of nuggets having high levels ofselected proteins. By use of the nuggets of the invention, nutritionbars are formulated to have elevated levels of protein, yet good tasteand other organoleptic properties.

The nuggets according to the invention include greater than 50 wt % of anon-soy protein preferably selected from the group consisting of milkprotein, rice protein and pea protein or mixtures thereof, especiallybetween 51 wt % and 99 wt %, more preferably between 52 wt % and 95 wt%, most preferably 55 wt % or above. The milk protein is preferably wheyprotein.

The nuggets preferably include one or more of: a coloring agent at lessthan 1 wt %, especially from 0.01 to 0.5 wt %; flour, especially riceflour, at from 2-8 wt %; and starch, which may for example be tapiocastarch or rice starch, at from 20-30 wt %.

The nuggets are preferably present in the nutritional bars of theinvention at levels from 5 to 75 wt %, more preferably from 10 to 50 wt%.

A difficulty associated with preparation of nuggets having elevatedlevels of certain proteins is the sensitivity of the proteins to hightemperatures typical of the extrusion process normally used to make thenuggets. Especially is this true of whey proteins. The nuggets of theinvention are preferably made using an extrusion process wherein theextrusion temperature is moderated so as to avoid damage to the selectednon-soy proteins and concomitant off-taste. In this preferred processaccording to the invention, extrusion is conducted at temperatures offrom 60° C. to 140° C., especially from 70° C. to 130° C., after whichthe protein is dried using a belt/conveyor drier and/or a fluid beddrier.

In an alternate method of making the nuggets according to the invention,supercritical fluids are injected into the extruder to permit use oflower extrusion temperatures, e.g., up to 95° C., and even the mosttemperature sensitive proteins, eg, whey. Supercritical fluid whichremains in the product after mixing is used to control the final productdensity by expansion of the product as it exits the extruder die.

The nuggets of the invention may, of course, be used in applicationsother than the nutritional bars herein.

Nuggets can have a variety of cross sections, e.g., circular,rectangular or square, and generally are bite sized particles having amaximum volume of 35 mm³ and a minimum volume of 4 mm³ preferablybetween 10 mm³ and 25 mm³. Typically, they will include at leastprotein, and will often include in addition one or more (preferably all)of: flour (especially rice flour), an additional starch source and,optionally a coloring agent.

For a more complete of the above and other features and advantages ofthe invention, reference should be made to the following description ofthe preferred embodiments

DETAILED DESCRIPTION OF THE INVENTION

Preferred sources for the non-soy protein used in the present inventioninclude sources of whey protein such as whey protein isolate and wheyprotein concentrate, sources of rice protein such as rice flour and riceprotein concentrate, and sources of pea protein. Additional proteinsources which may be present within the nugget or within the barexternal to the nugget include one or more of dairy protein source, suchas whole milk, skim milk, condensed milk, evaporated milk, whey, milksolids non-fat, etc. The dairy source may contribute dairy fat and/ornon-fat milk solids such as lactose and milk proteins, e.g. wheyproteins and caseins. Especially preferred, to minimize the caloricimpact, is the addition of protein as such rather than as one componentof a food ingredient such as whole milk. Preferred in this respect areprotein concentrates such as one or more of whey protein concentrate,milk protein concentrate, caseinates such as sodium and/or calciumcaseinate, isolated soy protein and soy protein concentrate. Totalprotein levels within the nutrition bars of the invention, includingprotein in the nuggets, are preferably within the range of 3 wt % to 40wt %, especially from 3 wt % to 20 wt %.

The nuggets of the invention include greater than 50 wt % of proteinselected from the group consisting of milk protein, rice protein and peaprotein and mixtures thereof, especially between 51 wt % and 99 wt %,more preferably between 52 wt % and 95 wt %, most preferably 55 wt % orabove. Other ingredients which may be present in the nuggets wouldinclude one or more of other proteins, such as those listed above,lipids, especially triglyceride fats, and carbohydrates, especiallystarches. Particularly where the nuggets are made using the moderatedtemperature extrusion process described below, it is advisable that theremaining ingredients be no more sensitive to heat degradation (e.g.,have the same or lower degradation point) than the selected non-soyprotein.

The source for any fat used in the nutrition bars, whether internal orexternal to the nugget, is preferably vegetable fat, such as forexample, cocoa butter, illipe, shea, palm, palm kernal, sal, soybean,safflower, cottonseed, coconut, rapeseed, canola, corn and sunfloweroils, or mixtures thereof. However, animal fats such as butter fat mayalso be used if consistent with the desired nutritional profile of theproduct. Preferably the amount of fat in either the nugget or the bar asa whole, is not more than 45 wt %, especially not more than 35 wt %,preferably from 0.5 to 10 wt %, still preferably from 0.5 to 5 wt %.

Carbohydrates can be used within the nugget at levels of from 1% to 49%.In addition to sweeteners mentioned below, examples of suitablecarbohydrates include starches such as are contained in rice flour,flour, tapioca flour, tapioca starch, and whole wheat flour and mixturesthereof. Carbohydrates can be used outside the nuggets within the bar aswell. Levels of carbohydrates in the bar as a whole will typicallycomprise from 5 wt % to 90 wt %, especially from 20% to 65 wt %.

If it is desired to include a bulking agent in the nutrition bars,within or external to the nuggets, a preferred bulking agent is inertpolydextrose. Other conventional bulking agents which may be used aloneor in combination include maltodextrin, sugar alcohols, corn syrupsolids, sugars or starches. Total bulking agent levels in the nuggets ofthe invention, and in the nutritional bars of the invention, willpreferably be from about 0% to 20 wt %, preferably 0.5% to 16%.Polydextrose may be obtained under the brand name Litesse.

Flavorings are preferably added to the nutrition bar in amounts thatwill impart a mild, pleasant flavor. The flavoring may be in the nuggetsor external to the nuggets in the bar, provided that processing is notadversely affected. The flavoring may be any of the commercial flavorsemployed in nutrition bars, such as varying types of cocoa, pure vanillaor artificial flavor, such as vanillin, ethyl vanillin, chocolate, malt,mint, yogurt powder, extracts, spices, such as cinnamon, nutmeg andginger, mixtures thereof, and the like. It will be appreciated that manyflavor variations may be obtained by combinations of the basic flavors.The nutrition bars are flavored to taste. Suitable flavorants may alsoinclude seasoning, such as salt, and imitation fruit or chocolateflavors either singly or in any suitable combination. Flavorings whichmask off-tastes from vitamins and/or minerals and other ingredients arepreferably included in the products of the invention, in the nuggetsand/or elsewhere in the product.

The nuggets and bar may include colorants, if desired, such as caramelcolorant.

If desired, the nuggets of the invention may include processing aidssuch as calcium chloride.

The nuggets may also include emulsifiers. Typical emulsifying agents maybe phospholipids and proteins or esters of long chain fatty acids and apolyhydric alcohol. Lecithin is an example. Fatty acid esters ofglycerol, polyglycerol esters of fatty acids, sorbitan esters of fattyacids and polyoxyethylene and polyoxypropylene esters of fatty acids maybe used but organoleptic properties, or course, must be considered.Mono- and di-glycerides are preferred. If present in the nuggets,emulsifiers may be used in amounts of about 0.03% to 0.3%, preferably0.05% to 0.1%. The same emulsifiers may also be present in the nutritionbar, again at levels overall of about 0.03% to 0.3%, preferably 0.05% to0.1%. Emulsifiers may be used in combination, as appropriate. Amongfiber sources which may be included in the compositions of the inventionare fructose oligosaccharides such as inulin, guar gum, gum arabic, gumacacia, oat fiber, cellulose and mixtures thereof. The compositionspreferably contain at least 2 grams of fiber per 56 g serving,especially at least 5 grams of fiber per serving. As indicated above,additional bulking agents such as maltodextrin, sugar alcohols, cornsyrup solids, sugars, starches and mixtures thereof may also be used.Total bulking agent levels in the products of the invention, includingfibers and other bulking agents, will preferably be from about 0% to20%, especially from 1 to 15 wt %. The fiber and the bulking agent maybe present in the nuggets or in the bar external to the nuggets providedthat processing is not impaired.

Carrageenan may be included in the bars of the invention, internal orexternal to the nuggets, eg, as a thickening and/or stabilizing agent.Cellulose gel and pectin are other thickeners which may be used alone orin combination.

Generally the nutrition bars which incorporate the nuggets of theinvention will be naturally sweetened. The sweetener may be included inthe nugget or in the bar provided that it does not interfere with theprocessing of the nugget (eg, sweetener will not be used in the nuggetif it is unstable at the moderate temperatures, where the moderatetemperature extrusion process is used). Natural sources of sweetnessinclude sucrose (liquid or solids), glucose, fructose, and corn syrup(liquid or solids), including high fructose corn syrup and high maltosecorn syrup and mixtures thereof. Other sweeteners include lactose,maltose, glycerine, brown sugar and galactose and mixtures thereof.Levels of sugars and sugar sources preferably result in sugar solidslevels of up to 50 wt %, preferably from 5 to 18 wt %, especially from10 to 17 wt % of the nutrition bar.

If it is desired to use artificial sweeteners, these may likewise bepresent in the nugget or within the bar external to the nugget, providedthat it does not interfere with processing. Any of the artificialsweeteners well known in the art may be used, such as aspartame,saccharine, Alitame® (obtainable from Pfizer), acesulfame K (obtainablefrom Hoechst), cyclamates, neotame, sucralbse, mixtures thereof and thelike. The sweeteners are used in varying amounts of about 0.005% to 1 wt% on the bar, preferably 0.007% to 0.73% depending on the sweetener, forexample. Aspartame may be used at a level of 0.05% to 0.15%, preferablyat a level of 0.07% to 0.11%. Acesulfame K is preferred at a level of0.09% to 0.15%.

Calcium is preferably present in the nutrition bars at from 10 to 30%RDA, especially about 25% RDA. The calcium source is preferablydicalcium phosphate. For example wt. % levels of dicalcium phosphate mayrange from 0.5 to 1.5%. In a preferred embodiment, the product isfortified with one or more vitamins and/or minerals and/or fibersources, in addition to the calcium source. These may include any or allof the following:

Ascorbic acid (Vitamin C), Tocopheryl Acetate (Vitamin E), Biotin(Vitamin H), Vitamin A Palmitate, Niacinamide (Vitamin B3), PotassiumIodide, d-Calcium Pantothenate (Vitamin B5), Cyanocobalamin (VitaminB12), Riboflavin (Vitamin B2), Thiamine Mononitrate (Vitamin B1),Molybdenum, Chromium, Selenium, Calcium Carbonate, Calcium Lactate,Manganese (as Manganese Sulfate), Magnesium (e.g., as magnesiumphosphate) Iron (as Ferric Orthophosphate) and Zinc (as Zinc Oxide). Thevitamins and minerals are preferably present at from 5 to 45% RDI,especially 5 to 20% RDI, most especially from about 15% RDI. Preferably,fiber sources are present in the product at greater than 0.5 wt. % anddo not exceed 6 wt. %, especially 5 wt. %. The vitamins and/or mineralsmay be included within, or external to, the nuggets, provided thatprocessing and human absorption are not impaired.

Ingredients which, if present, will generally be found within the barbut external to the nuggets include, but are not limited to, rolledoats, chocolate chips or other chocolate pieces, cookie and/or cookiedough pieces, such as oatmeal cookie pieces, brownie pieces, fruitpieces, such as dried cranberry, apple, etc., vegetable pieces such asrice, honey and acidulants such as malic and citric acids, leaveningagents such as sodium bicarbonate and peanut butter.

The nuggets of the invention are preferably made by one of two methods,although it is anticipated that alternative methods may be possible. Inthe first method according to the invention, the nuggets are made usingan extrusion process wherein the extrusion temperature is moderated soas to avoid damage to the whey (or other selected non-soy) proteins andconcomitant off-taste. In this process, it is expected that a blend ofthe selected proteins may, for instance, be made having a selectedprotein content of greater than 50 wt %, up to 70 or 80% or higher. Amoisture level of from 10 to 35 wt %, preferably from 15 to 25 wt %prior to extrusion is preferred. An extruder such as a twin screwextruder may be employed. Preferred extrusion temperatures are in therange of between 70 and 130° C., so as not to reach temperatures atwhich the proteins perceptibly degrade. This embodiment is preferred forrice and pea proteins, especially at the upper ends of the temperatureranges. After extrusion, a cutter may be used to cut the extrudates intothe desired length of the nuggets.

In accordance with the first method, the temperature sensitivity of theselected non-soy proteins makes it undesirable to achieve in theextruder temperatures high enough adequately to dry the extrudate.Therefore, a drying step is used subsequent to extrusion to achieve thedesired level of moisture. The drying step may comprise, for instance, abelt/conveyor dryer or a fluid bed dryer.

In the second process embodiment of the invention, super critical fluidsare used in the extruder, such as is set forth in Rizvi et al. U.S. Pat.Nos. 5,120,559 and/or 5,417,992, the disclosures of which are herebyincorporated by reference. In this embodiment, the nugget ingredients,eg non-soy protein, rice flour, additional carbohydrate and coloringagent, plus water, are introduced to the feed board and fed to theorifice from which the product is extruded. Water/moisture levels willgenerally be from 3-15, preferably 4-10 wt %. Prior to extrusion, asupercritical fluid, such as supercritical CO₂ is introduced into theextruder. Upon extrusion through the extrusion orifice, thesupercritical fluid expands, thereby imparting to the product adesirable expanded texture, e.g., puffing, which is otherwise onlypossible with elevated temperatures suitable for causing the moisture toboil. Since such elevated temperatures are desirably avoided to preventdegradation of the protein, use of the supercritical fluid permitsextrusion of a puffed product including temperature sensitive proteins,such as whey, by avoiding the elevated temperatures. In this alternativeprocess, the temperature in the extruder to which the nugget ingredientsare subjected is preferably not more than 95° C., especially within therange of from 70 to 90, especially up to 85° C., more preferably nohigher than 80° C.

For CO₂, the supercritical fluid may be at, for example, a pressure ofat least about 72.9 atmospheres and a temperature of at least about 31°C.

The nutritional bars may be made by known methods provided that thenuggets are not exposed to temperatures which cause degradation of theiringredients, especially the proteins.

Extruded nutritional bars may be made by cooking a syrup containingliquid (at ambient temperature) ingredients and then mixing with dryingredients. The mixture is then extruded onto a conveyor belt and cutwith a cutter. The nuggets of the invention are included among the dryingredients. The nuggets should only be added to the syrup when thesyrup is at a temperature below that at which any of the nuggetcomponents degrade. Supercritical fluid extrusion of the bar as a wholeat reduced temperatures can also be considered. Syrup ingredients mayinclude components such as corn syrup, glycerine, lecithin and soybeanoil or other liquid oils. In addition to the nuggets, other drycomponents include grains, flours, maltodextrin and milk powders.

Nutritional bars in the form of granola bars may be made by cooking thesyrup, adding the dry ingredients, blending the syrup and dryingredients in a blender, feeding the blended mix through rollers andcutting with a cutter.

The bars of the invention may be coated, eg with milk chocolate oryogurt flavored coating.

Typically, excluding moisture lost during processing, the uncoated barsof the invention will be made from 30-50 wt % syrup, especially 35-45%,and 50-70 wt % dry ingredients, especially 55-65 wt %. Generally coatedbars according to the invention will be made from 30-50 wt % syrup,especially 35-45 wt %, 40-50 wt % dry ingredients, especially 40-45% and0-30 wt % coating, especially 5-25 wt %, particularly 10-20 wt %coating.

Using one of the two preferred methods of the invention, it is believedthat nuggets having greater than 50 wt %, especially greater than 60%,more preferably greater than 70 or 80% of selected non-soy proteinsselected from the group consisting of milk protein, rice protein and peaprotein. can be achieved.

It can be expected that the nuggets of the invention may be used invarious types of nutrition bars including, without limitation, snackbars and meal replacement bars. One example would be granola bars. Thebars of the invention may be coated in whole or in part, e.g. with ayogurt flavored coating or a milk chocolate coating.

EXAMPLE 1 Prophetic

A blend of rice flour, whey protein isolate and whey protein concentrateis mixed to provide a protein content of between 50 and 70%. A twinscrew extruder with more than two barrel sections is used. The mixtureis extruded through a die of a predetermined shape. The temperature inthe two zones closest to the die is set between 70 and 130 C. Thetemperature of the mixture does not exceed 130° C. during extrusion. Thefeed material is fed into the extruder at a fixed rate with moisturecontent between 15 to 40%. At steady state the samples are collected.The excess moisture is dried using a belt/conveyor drier. A cutter isused to cut the extrudates to obtain the desired length of the nuggets.The nuggets thus obtained are included in a nutrition bar at a level of60 wt % and a good tasting bar, without appreciable off-taste, isobtained.

EXAMPLE 2 Prophetic

The process of Example 1 is carried out, except that the blend used is arice protein concentrate/rice flour blend having a protein contentbetween 50 and 80%, and a fluid bed dryer is employed to dry theproduct.

EXAMPLE 3 Prophetic

Whey protein (55 wt % based on dry ingredients), rice flour, starch andwater are mixed in an extrusion cooker to provide moisture content offrom 3 to 15 wt %. The mixture is heated to 85° C. A twin screw extruderwith more than two barrel sections is used. Supercritical carbon dioxideis mixed with the nugget ingredients. The mixture is extruded through adie of a predetermined shape. A cutter is used to cut the extrudates toget the desired length of the nuggets. The nuggets thus obtained areincluded in a nutrition bar at a level 6-60%. A good tasting bar,without appreciable off-taste, is obtained.

Unless stated otherwise or required by context, the terms “fat” and“oil” are used interchangeably herein. Unless otherwise stated orrequired by context, percentages are by weight.

It should be understood of course that the specific forms of theinvention herein illustrated and described are intended to berepresentative only, as certain changes may be made therein withoutdeparting from the clear teaching of the disclosure. Accordingly,reference should be made to the appended claims in determining the fullscope.

1. A nutritional bar comprising one or more extruded nuggets comprisinggreater than 50 wt % of a non-soy protein selected from the groupconsisting of whey protein, rice protein and pea protein.
 2. Thenutritional bar according to claim 1 wherein said non-soy protein ispresent in said nugget at a level of between 51 wt % and 99 wt %.
 3. Thenutritional bar according to claim 2 wherein said non-soy protein ispresent in said nugget at a level of between 52 wt % and 95 wt %.
 4. Thenutritional bar according to claim 1 wherein said non-soy protein ispresent in said nugget at a level of 55 wt % or above.
 5. Thenutritional bar according to claim 1 wherein said non-soy proteinincludes whey protein.
 6. A process for preparing a protein-containingnugget comprising extruding a composition comprising greater than 50 wt% of a non-soy protein selected from the group consisting of wheyprotein, rice protein and pea protein at a temperature not in excess of140° C. non-soy protein being present in said nugget at a level of 55wt. % or above.
 7. The process according to claim 6 wherein theextrusion takes place at a temperature within the range of from 70° C.through 130° C.
 8. (canceled)
 9. The process according to claim 6wherein said non-soy protein is present in said nugget at a level ofbetween 60 wt % and 95 wt %.
 10. The process according to claim 6wherein said non-soy protein is present in said nugget at a level of 70wt % or above.
 11. The process according to claim 6 wherein subsequentto said extrusion step, said ingredients are dried.
 12. The processaccording to claim 11 wherein said drying is conducted in abelt/conveyor dryer or a fluid bed dryer. 13-14. (canceled)
 15. Thenutrition bar according to claim 1 wherein said nugget further comprisesone or more minerals.
 16. The nutrition bar according to claim 15wherein the one or more minerals are selected from the group consistingof Molybdenum, Chromium, Selenium, Calcium, Manganese, Magnesium, Iron,and Zinc and mixtures thereof.
 17. The nutrition bar according to claim16 wherein the one or more minerals are present in the nugget at a levelfrom 10% RDI to 45% RDI.